Roofing



Sept. 11, 1934. R, P. MULLER ROOFING Filed Jan. 27, 1930 INVENT RALPH P. Mul. R

ATTORNEY Patented Sept. 11, 1934 PATENT OFFICE ROOFING Ralph P. Muller, St. George, Staten Island, N. Y., assignor to Seal-Kast Corporation, a corporation of Delaware Application January 27,

6 Claims.

'Ihis invention relates to the art of roofing and to the protection or insulation of such surfaces and contemplates a novel method of applying waterproofing materials, insulation, and erna-- mentation to all kinds of roofing structures.,Y An object of the invention is to provide an economical method of waterproofing and insulating. roof structures, which is simple of operation and which eliminates, to a great extent, the expense of handling quantities of vroofing units and other materials and the expense of transporting the same, not only to the point of destination, but from the ground to the roof.'

Another object is to provide a satisfactory protection for roof structures which is not only absolutely waterproof but` is also ornamental and which can be applied to any such roof surface in practically a single operation.

Another object is to provide a roofing material particularly adapted to be used in re-roong jobs directly upon the old material of a roof structure over which it is impractical or impossible to lay any kind of known roofing products, such as tin or galvanized iron roofs.

Roofing material has heretofore been factorymade in various forms, and has required a great deal of handling and transporting before it is` available at the job. Roofing material has also been applied on the job by various methods which include mopping the surface to be coated with liquid asphalt, laying impregnated and/or water- Aproofed paper thereover, and mopping the surface again and applying grit over the top to afford a wear-resisting and heat-resisting surface. The former procedure has necessitated considerable Aexpenditures for transportation and handling be'- fore the product is available on the job and-has also necessitated large labor costs on the job. The latter procedure has been found expensive because of the large amount of manual labor necessary to complete the various steps which must be carried out to obtain the completed Water-proof application. An object of the invention is to eliminate or diminish the above-mentioned disadvantages andto produce a `cheap and easily constructed Water-proof roof structure, in

which the application of the material is accomplished with great rapidity and with very little labor expense at the point of construction.

Other objects of this invention will hereinafter be set forth, or Will be apparentfrom the description and the drawing, in which is illustrated one method of operation for carrying out the 55 invention.

1930, serial No. 423,885

(ci. 10s-e) Theinvention, however, is not intended tobe restricted to any particular application of s uch operation, or to any specific method of operation, or to any of various details thereof, herein shown and described, as'the same may be modified in 60 various particulars or be applied in many varied relations without departing from the spirit and scope of the claimed invention, the practical embodiments herein illustrated and described merely being descriptive of some of the various forms and modifications in'which the invention might be embodied.

On the drawing', in which the same reference characters refer to the same partsthroughout, and in which is disclosed such method of operation:

The figure is a perspective view, illustrating the manner of application of the invention to a roof construction, shown as under repair.

The invention consists essentially in forcing, by compressed air or any fluid pressure, acontinuous supply of waterproofing compound, in liquid state, up to and onto the roof surface to be coated, and, if desired, or if the character of the coating permits, simultaneously or immediately thereafter, forcing under similar pressure, a continuous supply of grit surfacing thereover and therein, thereby firmly imbedding, by such pressure, the grit into said Waterproofing compound.

'I'he process is applied particularly in connec- 85 tion with the application of waterproofing compound for roofing purposes, wherein, under pressure of the gaseous medium which is finally effective to drive tlie substances against the surface to be coated, or by means of some similar method of pumping or conveying the liquid or semiliquid, and/or the granular, material from the source of supply to the roof or similar surface to be operated upon, the particular roofing compound and/or the grit are brought in a continuous stream and continuously applied 'to the surface to be coated.

The pressure of the driving medium preferably is regulated so as to carry the base coating and/or waterproofing uid, and if grit material is used, the grit material, forcibly onto thesurface to be coated; because of the liquid, or semiliquid application of the roof surface and the force of its applicationh all cracks, holes and interstices will be filled up and sealed by the Waterproofng compound. The grit can be applied in any desired manner, in plain, ornamental, or' variegated designs and colors. The term, grit, is used in this application for convenience in order refer to all kinds of material reduced to 1.10

small particle sizes which is adapted to serve as a surfacing or ornamenting medium for roofing, insulating, andl covering materials. Preferably crushed slate is used because of its relatively low price, availability and range of color,.but it is understood that any material capable of reduction to relatively small sizes, such as glass shards, metal filings, sand, vitrified tile, porcelain, or other materials, may be used.

The application is accomplished by means of apparatus which will forcibly convey fluid waterprooiing material and surfacing material from one position to another and then feed such materials to a nozzle or nozzles through which the materials are delivered onto the roof surface to be protected. Preferably the waterproofing coatingis applied slightly in advance of the grit so that the surface is thoroughly coated with the waterproofing material slightly prior to the time when the grit is applied, thus ensuring a sticky.

or mastic layer on which and into which the grit may be embedded. The pressure of the waterproofing liquid is regulated as desired and should be strong enough to ensure penetration into all available cracks, crevices, holes or graining in the covering surface, yet such pressure should not be so great as to cause the liquidfto be splashed away from the immediate area of application. 'I'he invention is not to be limited to the use of any particular coating material as any coating material, such as asphalt emulsiiled in liquids at ordinary temperatures, or materials which can be made liquid during application and which subsequently harden, dry or set into tough, exible, solid or semi-solid waterproof bodies or films,

can be used.

I contemplate spraying metals in molten state on roofs which have or have not been treated with. additional waterproofing coatings. In such case, the molten metal is spread from an' apparatus which melts a continuously fed strip or wire of metal and ejects molten uid in a finely atomized spray. Preferably an old surface is -rst treated with bituminous material and grit in order to preserve the same and to provide a strong key for subsequent applications of material, and also to provide a fire-proof base therefor, the molten metal being then applied. The bituminous material serves as waterproofing and insulating material and is not subject to corrosion as by salt air or by the presence of gases in the air which ordinarily attack metal roofs. This material thus provides additional protection against weathering, should the outer metal nlm be, by chance, perforated. In addition to the above mentioned advantages of the described construction, the uniform metallic film seals in the bituminous compound and the volatile oils thereof, so that no loss results in the waterproofing or insulating qualities of the material.

By virtue of thefforcible feeding alluded to, the water-proof Acoating is rmly adhered to the surface and forced into any holes, cracks or crevices which are present, thus ensuring that the roof structure is thoroughly waterproof. If'the cracks or holes are large, more than one application-may be required, but under ordinary circumstances one coating is sufhcient. The invention is well adapted for use on re-roofing jobs where it is either undesirable, impossible or impracticable to apply known forms of roong material owing to the characteristics of the ma terial comprising the surface. The cracks and holes are completely lled with waterproong liquid which, after solidifying, renders the surface impervious to the weather, and prevents loose or open edges or joints or flaps under which water or wind could ordinarily penetrate.

In applying color designs to the roof, the surfacing material, i. e., the grit, may be supplied from a separate hopper or hoppers or other sources of supply. In such case, means are provided for controlling the color and/or quantity of grit supplied and/or the rate. of mixing, so that the surfacing material may be applied to the coated surface in any desired manner.

On the drawing, there is illustrated, in simple manner, a method of application of the invention, particularly to a roof commotionl 10, here shown as having a boundary wall 12. The roof surface 14 itself is shown as formed by boards 16, between which are left crevices 18. For illustrative purposes, at a chimney 20, a broken portion 22 is shown, such broken portion to be repaired, such repair being one-of the possible features of construction work which may be carried out by application ofthe invention herein.

In making the roof construction, in accordance with this invention, material, such as an asphalt emulsion. is first sprayed upon the surface to be protected. Preferably, following closely after the application of the emulsion, grit particles are sprayed upon the surface coated with the emulsion. If desired, a metallic spray may be coordinated with oneor both of the other sprays, as herein described.

On the drawing, nozzles 24 and 26 are intended to illustrate, respectively, a nozzle spraying the asphalt emulsio ,and a nozzle spraying the grit particles. As shown, the emulsion has coated over the root surface defined by boards 16, and has even been extended to seal crevices 28 at the junction of roof surface 14 with boundary wall 12 and chimney 20. Coating 30, for this purpose, may be extended up the side of the boundary .wall a sufllcient distance to assure a proper seal at this position.

Following .immediately upon the deposit of coating 30, or at a sumcient interval that the coating will still be plastic and suillciently iiuid in order to receive the sprayed particles, permit them to become'imbeddedto a slight degree in the coating, and' become bonded to the coating, nozzle 26 is made effective. Grit lparticles 32 thus define their layer 34. As here shown, the two spraying operations are carried on substantially simultaneously, so that a section 36 of coating4 30 will beelear of-particlesfor a predetermined interval to permit a degree of hardening of the coating before the particles fall upon it.

Whenv broken portion 22 will be reached-and suchv portion is generally nothing more than a frayed orworn section of the timbers or other defects in the materials,the coating composition will be effective to ll up that broken portion completely, sealing it as it does crevices 18 and other similar defects in the ordinary roof surface.

Many other changes could be effected in the methods of operation set forth, and in specific details thereof, without substantially departing from the invention intended to be dened in the claims, the specific description herein being for embodiments capable of carrying out the spirit of the invention.

Having thus described my invention, I claim:

1. The construction of a moisture-impervious roof construction from a roof constructionhaving inherent moisture-pervious characteristics, in

iso

which the moisture-pervious roof construction has been located and assembled in position for use as such, which includes the steps of: forcing, under pressure, a continuous stream of .liquid Water-proofing compound to and spraying the compound onto the surface of the moisture-pervious roof constructionto formv a substantially unitary coating for the roof construction; and then spraying a continuous stream of protective material onto the coating.

2. The construction of a moisture-impervious roof construction from a roof construction having inherent moisture-pervious characteristics in which the moisture-pervious roof construction has been located and assembled in position for use as i such, which includes the steps of: forcing, under pressure, a continuous stream of liquid Waterprooiing compound to and spraying the compound onto the surface of the moisture-pervious roof construction to form a substantially unitary coat-` ing for the roof construction.; and then spraying under pressure a continuous stream of grit particles onto the coating. l 3. The construction of a moisture-impervious roof construction from a roof construction having inherent moisture-pervious characteristics, in which the moisturepervious roof construction has been located and assembled in position for use as such, which includes the steps of: forcing, under pressure, a continuous streamof liquid Water-proofing compound to and spraying the compound onto the surface of the moisture-per vious roof construction to form a substantially unitary coating for the roof construction; and then depositing metallic particles upon the coating to form a substantially continuous metallic sheet for the layer.

4. The construction of a moisture-impervious roof-,construction from a roof construction having inherent moisture-pervious characteristics, in which the moisture-pervious roof construction has been located and assembled in position for use as such, which includes the steps of: forcing, under pressure, a continuous streamof liquid Water-proofing compound to and spraying the compound onto the surface of the moisture-pervious roof construction to form a substantially unitary coating for ythe roof construction; and then atomizing metallic particles and driving them against the coating to unit them and form a substantially continuous metallic cover for the coating.

5. 'I'he construction of a moisture-impervious roof construction from a roofv construction having inherent moisture-pervious characteristics in which the moisture-pervious roof construction has been located and assembled in position for use as such, which includes the steps' of: forcing, under pressure, a continuous stream of liquid water-proofing compound to and spraying the compound onto the surface of the moisture-pervious roof construction to form a substantially unitary coating for the roof construction; and then, while the coating remains sufficiently plastic, spraying a continuous stream of grit particles at the coating under a suiiicient pressure to cause the particles to become imbedded in the plastic coating.

6. The construction of a moisture-impervious roof construction from a roof construction having inherent moisture-pervious characteristics in which the moisture-pervious -roof construction has been located and assembled in position for use as such, which includes the vsteps of: forcing, under pressure, a continuous stream of liquid water-proong compound to and spraying the compound onto the surface of the moisture-pervious roof construction to form a substantially unitary coating vfor the roof construction; then, while the coating remains suiiiciently plastic, ne spraying a continuous stream of grit particles at the coating under a sufficient pressure to cause the particlesl to become imbedded in the plastic coatf ing; and -thereafter atomizing metallic particles in a plasticl state and driving them against the coating and the grit particles to unite the particles and form a substantially continuous metallic cover for coating and particles.

' RALPH P. MULLER.. 120 

